Method for producing fluorinated organic compounds

ABSTRACT

Disclosed are processes for the production of fluorinated olefins, preferably adapted to commercialization of CF 3 CF═CH 2  (1234yf). In certain preferred embodiments the processes comprise first exposing a compound of Formula (IA) 
       C(X) 2 ═CClC(X) 3   (IA) 
     where each X is independently F, Cl or H, preferably CCl 2 ═CClCH 2 Cl, to one or more sets of reaction conditions, but preferably a substantially single set of reaction conditions, effective to produce at least one chlorofluoropropane, preferably in accordance with Formula (IB): 
       CF 3 CClXC(X) 3   Formula (IB) 
     where each X′ is independently F, Cl or H, and then exposing the compound of Formula (IB) to one or more sets of reaction conditions, but preferably a substantially single set of reaction conditions, effective to produce a compound of Formula (II) 
       CF 3 CF═CHZ  (II) 
     where Z is H, F, Cl, I or Br.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is related to and claims the priority benefit of U.S.application Ser. Nos. 11/619,592, filed Jan. 3, 2007 and published asU.S. 20070197842, which is a regular application claiming the prioritybenefit of U.S. Provisional Application No. 60/755,485, filed Jan. 3,2006, and U.S. Provisional Application 60/953,528, filed Aug. 2, 2007,which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

(1) Field of Invention

This invention relates to novel methods for preparing fluorinatedorganic compounds, and more particularly to methods of producingfluorinated olefins having a fluorine on an unsaturated non-terminalcarbon.

(2) Description of Related Art

Hydrofluorocarbons (HFCs), in particular hydrofluoroalkenes such astetrafluoropropenes (including 2,3,3,3-tetrafluoro-1-propene(HFO-1234yf) and 1,3,3,3-tetrafluoro-1-propene (HFO-1234ze)) have beendisclosed to be effective refrigerants, fire extinguishants, heattransfer media, propellants, foaming agents, blowing agents, gaseousdielectrics, sterilant carriers, polymerization media, particulateremoval fluids, carrier fluids, buffing abrasive agents, displacementdrying agents and power cycle working fluids. Unlike chlorofluorocarbons(CFCs) and hydrochlorofluorocarbons (HCFCs), both of which potentiallydamage the Earth's ozone layer, HFCs do not contain chlorine and, thus,pose no threat to the ozone layer.

Several methods of preparing hydrofluoroalkenes are known. For example,U.S. Pat. No. 4,900,874 (Ihara, et. al) describes a method of makingfluorine containing olefins by contacting hydrogen gas with fluorinatedalcohols. Although this appears to be a relatively high-yield process,commercial handling of hydrogen gas at high temperature is generallyunsafe. Also, the cost of producing hydrogen gas, such as building anon-site hydrogen plant, can be, in many situations, prohibitive.

U.S. Pat. No. 2,931,840 (Marquis) describes a method of making fluorinecontaining olefins by pyrolysis of methyl chloride andtetrafluoroethylene or chlorodifluoromethane. This process produces arelatively low yield and a very large percentage of unwanted and/orunimportant byproducts.

The preparation of HFO-1234yf from trifluoroacetylacetone and sulfurtetrafluoride has been described. See Banks, et al., Journal of FluorineChemistry, Vol. 82, Iss. 2, p. 171-174 (1997). Also, U.S. Pat. No.5,162,594 (Krespan) discloses a process wherein tetrafluoroethylene isreacted with another fluorinated ethylene in the liquid phase to producea polyfluoroolefin product.

SUMMARY OF INVENTION

One aspect of the invention involves methods of producinghydrofluoroalkenes, more preferably fluorinated olefins having afluorine on an unsaturated non-terminal carbon and even more preferablyin certain preferred embodiments 2,3,3,3-tetrafluoro-1-propene(HFO-1234yf). In preferred forms, this aspect of the invention isdirected to methods comprising converting at least one compound ofFormula (I):

C(X)_(m)CCl(Y)_(n)C(X)_(m)  (I)

to at least one compound of Formula (II)

CF₃CF═CHZ  (II)

where each X, Y and Z is independently H, F, Cl, I or Br, and each m isindependently 1, 2 or 3, preferably 2 or 3, and n is 0 or 1. In certainpreferred embodiments, compounds of Formula I include CH₂═CClCCl₃,CCl₂═CClCH₂Cl, and 1,1,1,2,3-pentachloropropane. As used herein andthroughout, unless specifically indicated otherwise, the term“converting” includes directly converting (for example, in a singlereaction or under essentially one set of reaction conditions) andindirectly converting (for example, through two or more reactions orusing more than a single set of reaction conditions).

In certain preferred embodiments of the invention, the compound ofFormula (I) comprises a compound wherein n is 0, each X is independentlyH or Cl, and Z is H. Such preferred embodiments include converting atleast one C3 alkene in accordance with Formula (IA):

C(X)₂═CClC(X)₃  (IA)

to at least one compound of formula (II)

CF₃CF═CHZ  (II)

where each X is independently H or Cl. Preferably the one or morecompounds of Formula (IA) are tetrachloropropene(s), and are even morepreferably selected from the group consisting of CH₂═CClCCl₃,CCl₂═CClCH₂Cl, and combinations of these. In certain highly preferredembodiments, the at least one C3 alkene in accordance with Formula (IA)comprises, and preferably comprises in a major proportion based on allcompounds of Formula (I), CCl₂═CClCH₂Cl.

In certain preferred embodiments the converting step comprises firstexposing the compound of Formula (I), and preferably Formula (IA), andeven more preferably CCl₂═CClCH₂Cl, to one or more sets of reactionconditions, but preferably a substantially single set of reactionconditions, effective to produce at least one chlorofluoropropane, morepreferably a propane in accordance with Formula (IB):

CF₃CClXC(X)₃  Formula (IB)

where each X is independently F, Cl or H, preferably where one X is Fand the remaining X's are H, and then exposing the compound of Formula(IB) to one or more sets of reaction conditions, but preferably asubstantially single set of reaction conditions, effective to produce acompound of Formula (II), most preferably HFO-1234yf. In certainpreferred embodiments, at least one of said X in Formula (IB) is Cl. Insuch embodiments, it is generally preferred that X on the non-terminalcarbon is H, and even more preferably that in addition that at leasttwo, and more preferably all three X on the terminal carbon are also H.

As used herein, the term “substantially single set of reactionconditions” means that the reaction is controlled to correspond to bewithin a set of reaction parameters that would ordinarily be consideredto be a single stage or unit operation. As those skilled in the art willappreciate, such conditions permit a degree of design variability withineach of the process parameters relevant to the conversion step.

The preferred conversion step of the present invention is preferablycarried out under conditions, including the use of one or morereactions, effective to provide an overall Formula (I) conversion of atleast about 50%, more preferably at least about 75%, and even morepreferably at least about 90%. In certain preferred embodiments theoverall conversion of Formula (I) is at least about 95%, and morepreferably at least about 97%. Further, in certain preferredembodiments, the step of converting the compound of Formula (I) toproduce a compound of Formula (II) is conducted under conditionseffective to provide an overall Formula (II) yield of at least about75%, more preferably at least about 85%, and more preferably at leastabout 90%. In certain preferred embodiments an overall yield of about95% or greater is achieved.

In the preferred embodiments in which the conversion step comprisesexposing a compound of Formula (I), and even more preferablyCCl₂═CClCH₂Cl, to one or more sets of reaction conditions effective toproduce at least one chlorofluoropropane, more preferably a propane inaccordance with Formula (IB), such an exposing step preferably comprisesexposing the compound of Formula (I) to one or more set of reactionconditions, but preferably substantially a single set of reactionconditions, effective to provide an overall conversion of Formula (I),and preferably Formula (IA) of at least about 75%, and more preferablyat least about 90%, and more preferably at least about 97%, suchconditions also preferably being effective to provide a Formula (IB)selectivity yield of at least about 10%, more preferably at least about15%, and even more preferably at least about 20%.

One preferred aspect of the present invention provides a process for theproduction of 2-chloro-1,1,1,2-tetrafluoropropane (HCFC244bb) comprisingreacting a compound selected from the group consisting of1,1,2,3-tetrachloropropene, 1,1,1,2,3-pentachloropropane (HCC-240 db),2,3,3,3-tetrachloropropene and combinations of these with a fluorinatingagent, preferably hydrogen fluoride, in a liquid phase reaction vesselin the presence of a liquid phase fluorination catalyst.

Another preferred aspect of the invention provides a process for theproduction of 2,3,3,3-tetrafluoropropene comprising (i) reacting,preferably in a continuous process, at least one compound selected fromthe group consisting of 1,1,2,3-tetrachloropropene,1,1,1,2,3-pentachloropropane (HCC-240 db), and2,3,3,3-tetrachloropropene with a fluorinating agent, preferablyhydrogen fluoride, in a liquid phase reaction in the presence of aliquid phase fluorination catalyst to produce a reaction productcomprising 2-chloro-1,1,1,2-tetrafluoropropane (HCFC-244bb); and then(ii) reacting, preferably by dehydrohalogenating, the2-chloro-1,1,1,2-tetrafluoropropane (HCFC-244bb) under conditionseffective to produce 2,3,3,3-tetrafluoropropene.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a chart showing the yield of HFC-1234yf according to anembodiment of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

One beneficial aspect of the present invention is that it enables theproduction of desirable fluoroolefins, preferably C3 fluoroolefins,using relatively high conversion reactions. Furthermore, the presentmethods in certain preferred embodiments permit the production of thedesirable fluoroolefins, either directly or indirectly, from relativelyattractive starting materials. For example, tetrachloropropene, and1,1,2,3 tetrachloropropene (CCl₂═CClCH₂Cl) in particular, is a compoundthat in certain embodiments is an advantageous starting material.

In certain preferred embodiments, at least a first compound inaccordance with Formula (I), and preferably a compound in accordancewith Formula (IA), is exposed to one or more reaction conditionseffective to produce a second compound in accordance with Formula (I),and preferably a compound in accordance with Formula (IB), which in turnis exposed to one or more reaction conditions effective to produce areaction product containing one or more of the desired fluoroolefins,preferably one or more compounds of Formula (II), and even morepreferably HFO-1234yf. Thus, in preferred embodiments, the conversionstep comprises a series of at least two reaction stages or conditions.In one preferred aspect of the present invention, the conversion stepcomprises: (a) reacting a compound of Formula (IA), such astetrachloropropene, preferably in a liquid phase reaction in thepresence of at least a first catalyst to produce at least one compoundof Formula (IB), such as a monochloro-tetrafluoro-propane, preferably2-chloro-1,1,1,2-tetrafluoropropane (HFC-244bb); and (b) reacting saidcompound of Formula (IB), in a gas and/or liquid phase, to produce thedesired HFO, preferably HFO-1234yf.

In certain preferred embodiments, the present methods compriseconverting at least one tetrachloropropene and/or at least onepentachloropropane to a reaction product containing the desiredtetrafluoropropene, preferably 2,3,3,3-tetrafluoropropene (HFO-1234yf).Although it is contemplated that the converting step in certainembodiments may effectively be carried out in a single reaction stageand/or under a single set of reaction conditions, it is preferred inmany embodiments that the converting steps comprise a series of tworeaction stages or conditions. In one preferred aspect of the presentinvention, the conversion step comprises: (a) reacting at least onetetrachloropropene (preferably, 1,1,2,3-tetrachloropropene and/or2,3,3,3-tetrachloropropene), or at least one pentachloropropane(1,1,1,2,3-pentachloropropane) or mixtures of two or more thereof, in aliquid and/or gas phase reaction in the presence of at least a firstcatalyst to produce at least one C3 hydrochlorofluorocarbon such as amono-chloro-tetrafluoro-propane, preferably HCFC-244bb; and (b) reactingsaid C3 hydrochlorofluorocarbon, such as a monochloro-tetrafluoropropanecompound, in a gas and/or liquid phase and preferably in the presence ofat least a catalyst, preferably a second catalyst which is differentthan the first catalyst, to produce the desired tetrafluoropropene,preferably HFO-1234yf.

Each of the preferred reaction steps is described in detail below, withthe headings being used for convenience but not necessarily by way oflimitation.

I. Fluorination of the Compound of Formula (IA)

One preferred reaction step in accordance with the present invention maybe described by those reactions in which the compound of Formula (IA) isfluorinated to produce a compound of Formula (IB). In certain preferredembodiments, especially embodiments in which the compound of Formula(IA) comprises C(X)₂═CClC(X)₃, where each X is independently H or Cl,the present converting step comprises reacting said Formula (IA)compound(s) by fluorinating, preferably in a liquid phase and with HF asa fluorinating agent, said compound(s) to produce a compound of Formula(IB), namely,

CF₃CClX′C(X′)₃  Formula (IB)

where each X′ is independently F, Cl or H. The preferred fluorination ofthe compound of Formula (IA) is preferably carried out under conditionseffective to provide a Formula (IA) conversion of at least about 50%,more preferably at least about 75%, and even more preferably at leastabout 90%. In certain preferred embodiments the conversion is at leastabout 95%, and more preferably at least about 97%. Further, in certainpreferred embodiments, the conversion of the compound of Formula (IA)comprises reacting such compound under conditions effective to produceat least one compound of Formula (IB), such asmonochlorotetrafluoropropane (preferably HCFC-244bb) at a selectivity ofat least about 10%, more preferably at least about 15%, and morepreferably at least about 20%.

In certain preferred embodiments in which the feed material comprisestetrachloropropene, the present converting step is carried out underconditions effective to provide a tetrachloropropene conversion of atleast about 40%, more preferably at least about 55%, and even morepreferably at least about 70%. In certain preferred embodiments theconversion of tetrachloropropene is at least about 90%, and morepreferably about 100%. Further, in certain preferred embodiments, theconversion of the tetrachloropropene to produce a C3hydrochlorofluorocarbon is conducted under conditions effective toprovide a C3 hydrochlorofluorocarbon selectivity of at least about 85%,more preferably at least about 90%, and more preferably at least about95%, and even more preferably about 100%.

In a particularly preferred embodiment, the invention relates to acontinuous method for producing a compound of Formula (IB), preferablyincluding 2-chloro-1,1,1,2-tetrafluoropropane (HCFC-244bb), by either aliquid phase fluorination, a vapor phase fluorination, or a combinationof liquid and vapor phase fluorinations. In certain preferredembodiments, the feed to the fluorination reaction comprises at leastone chlorocarbon or mixed chlorocarbon feed material, preferablyselected from the group consisting of 1,1,1,2,3-pentachloropropane(HCC-240 db), 2,3,3,3-tetrachloropropene, and1,1,2,3,-tetrachloropropene (HCC-1230xa. The compounds in the feed arereacted with a fluorinating agent, such as hydrogen fluoride, to producea reaction product stream comprising a compound according to Formula(IB), such as 2-chloro-1,1,1,2-tetrafluoropropane, hydrogen fluoride,and hydrogen chloride.

In certain embodiments, it is preferred that the fluorination reactionstep is carried out in the liquid phase, and preferably under asubstantially single set of reaction conditions, and it is contemplatedthat the reaction can be carried out batch wise, continuous, or acombination of these, with continuous reaction being preferred. In apreferred form of a continuous process, the Formula (I) compound, suchas 1,1,2,3-tetrachloropropene, and the fluorinating agent, such as HF,are preferably fed, preferably substantially simultaneously, to thereactor after the reactor reaches the desired temperature. Thetemperature and pressure of the fluorination reaction are generallywithin about the same range for both the batch and continuous modes ofoperation.

For embodiments in which the reaction comprises a liquid phase reaction,preferably a catalytic process is used. In general, it is contemplatedthat any liquid phase fluorination catalyst may be used. Lewis acidcatalyst, metal-halide catalysts, including antimony halides, tinhalides, tantalum halides, titanium halides, transition metal-halides,such as iron halides, niobium halide, and molybdenum halide, transitionmetal oxides, Group IVb metal halides, a Group Vb metal halides,fluorinated chrome halide, a fluorinated chrome oxide and combinationsof two or more of these, are preferred in certain embodiments. Metalchlorides and metal fluorides are particularly preferred. Examples ofparticularly preferred catalysts of this type include SbCl₅, SbCl₃,SbF₅, SnCl₄, TaCl₅, NbCl₅, MoCl₆, TiCl₄, FeCl₃, a fluorinated species ofSbCl₅, a fluorinated species of SbCl₃, a fluorinated species of SnCl₄, afluorinated species of TaCl₅, a fluorinated species of TiC₄, afluorinated species of NbCl₅, a fluorinated species of MoCl₆, afluorinated species of FeCl₃, and combinations of two or more of these.Pentavalent metal halide, particularly pentavalent antimony halides arepreferred in many embodiments. Antimony chlorides, such as antimonypentachloride, and/or fluorinated antimony chlorides are preferred inmany embodiments.

In certain preferred embodiments, a liquid phase catalyst as describedabove is charged into a fluorination reactor prior to heating thereactor. The catalyst may (or may not) be activated with anhydroushydrogen fluoride HF (hydrogen fluoride gas) and/or Cl₂ (chlorine gas)before use depending on the state of the catalyst.

In preferred liquid phase fluorination of Formula (I) compounds,preferably Formula (IA) compounds, the reaction is at least partially acatalyzed reaction, and is preferably carried out on a continuous basisby introducing a stream containing the compound of Formula (I),preferably Formula (IA), into one or more reaction vessels. The streamcontaining the compound of Formula (I), and preferably Formula (IA),which may be preheated if desired, is introduced into a reaction vessel,which is maintained at the desired temperature, preferably from about30° C. to about 200° C., more preferably from about 50° C. to about 150°C., more preferably from about 75° C. to about 125° C., even morepreferably in certain embodiments from about 90° C. to about 110° C.,wherein it is preferably contacted with catalyst and fluorinating agent,such as HF.

It is generally preferred that the fluorinating agent is present in thereactor in substantial excess. For example, for embodiments in which thefluorinating agent is HF, it is preferred that the reactor be fed withHF in an amount to produce an HF:Formula (IB) ratio in the reactorproduct stream (on a molar basis) of at least about 4:1, more preferablyfrom about 4:1 to about 50:1, more preferably from about 4:1 to about30:1 and most preferably from about 5:1 to about 20:1.

With respect to the feeds to the reactor, including the fluorinationagent, it is generally considered that water will react with anddeactivate the catalyst. Therefore it is preferred that the feed besubstantially free of water. With respect to embodiments in which HF isused as a fluorinating agent, substantially anhydrous HF is preferred.By “substantially anhydrous” is meant that the HF contains less thanabout 0.05 weight % water and preferably contains less than about 0.02weight % water. However, one of ordinary skill in the art willappreciate that the presence of water in the catalyst can be compensatedfor by increasing the amount of catalyst used. HF suitable for use inthe reaction may be purchased from Honeywell International Inc. ofMorristown, N.J.

Although it is contemplated that residence times in the reactor may varywidely within the scope of the present invention, it is preferred incertain embodiments that for continuous reactions the residence time isrelatively short. The residence time or contact time in certainpreferred embodiments is from about 1 second to about 2 hours,preferably from about 5 seconds to about 1 hour and most preferably fromabout 10 seconds to about 30 minutes. The quantity of catalyst isgenerally selected to ensure that the desired level of fluorination isachieved in view of the other process conditions which apply, such asthe residence times described above. For example, less than about 5seconds, more preferably less than about 3 seconds, and even morepreferably about 2 seconds or less.

Without necessarily being bound to any particular theory of operation itis believed that the preferred fluorination reaction proceedings inaccordance with the following reaction equation:

It is expected that by-products of the reaction will include CF₃CCl═CH₂(HFO-1233xf), CClF₂CCl═CH₂ (HFO-1232xf), and that one or both of thesecould be recycled, completely or partially, to improve the overall yieldof the desired CF₃CClFCH₃ (HCFC-244bb).

In general, it is contemplated that any reactor suitable for afluorination reaction may be used in accordance with the preferredaspects of the present invention. Preferably the vessel is comprised ofmaterials which are resistant to corrosion as Hastelloy, Inconel, Moneland/or fluoropolymer-lined. Such liquid phase fluorination reactors arewell known in the art.

Preferably in certain embodiments, the vessel contains catalyst, forexample a fixed or fluid catalyst bed, packed with a suitablefluorination catalyst, with suitable means to ensure that the reactionmixture is maintained with the desired reaction temperature range.

In general it is also contemplated that a wide variety of reactionpressures may be used for the fluorination reaction, depending again onrelevant factors such as the specific catalyst being used, thetemperature of the reaction, the amount of fluorinating agent beingused, and other factors. The reaction pressure can be, for example,superatmospheric, atmospheric or under vacuum and in certain preferredembodiments is from about 5 to about 200 psia, and in certainembodiments from about 30 to about 175 psia and most preferably about 60psia to about 150 psia.

In certain embodiments, an inert diluent gas, such as nitrogen, may beused in combination with the other reactor feed(s).

It is contemplated that the amount of catalyst used will vary dependingon the particular parameters present in each embodiment. In certainpreferred embodiments, the catalyst is present in an amount of fromabout 2% to about 80%, and preferably from about 5% to about 50%, andmost preferably from about 10% to about 20%, based on the mole percentof the desired reaction product, preferably a compound in accordancewith formula (IB), and even more preferably HCFC-244bb. Fluorinationcatalysts having a purity of at least 98% are preferred.

The catalysts can be readily regenerated by any means known in the artif they become deactivated. One suitable method of regenerating thecatalyst involves flowing a stream of chlorine through the catalyst. Forexample, from about 0.002 to about 0.2 lb per hour of chlorine can beadded to the liquid phase reaction for every pound of liquid phasefluorination catalyst. This may be done, for example, for from about 1to about 2 hours or continuously at a temperature of from about 65° C.to about 100° C.

In another embodiment, the fluorination reaction is done in thevapor-phase. In preferred aspects of the vapor phase reaction, thefluorinating agent, such as HF (hydrogen fluoride gas) is fedcontinuously through the catalyst bed. After a short time withsubstantially only the HF feed stream, a compound according to Formula(I), and preferably Formula IA, such as 1,1,2,3-tetrachloropropene, isfed continuously through the catalyst bed at a fluorinating agentFormula (I) mole ratio, preferably HF/1,1,2,3-tetrachloropropene moleratio, of about 4:1 to about 50:1 and preferably of about 4:1 to about30:1 and more preferably of about 5:1 to about 20:1. The reaction ispreferably carried out at a temperature of from about 30° C. to about200° C. (preferably from about 50° C. to about 120° C.) and at apressure of about 5 psia to about 200 psia (pounds per square inchabsolute) (preferably from about 30 psia to about 175 psia). Thecatalyst may be supported on a substrate, such as on activated carbon,or may be unsupported or free-standing. It may be preferred in certainembodiments to activate the catalyst, such as with anhydrous hydrogenfluoride HF (hydrogen fluoride gas) and/or Cl₂ (chlorine gas) before usedepending on the state of the catalyst. If desired, the catalyst can bekept activated by the continuous or batch addition of Cl₂ or a similaroxidizing agent.

Any vapor phase fluorination catalyst may be used in the invention. Anon-exhaustive list include Lewis acids, transition metal halides,transition metal oxides, Group IVb metal halides, a Group Vb metalhalides, or combinations thereof. Non-exclusive examples of liquid phasefluorination catalysts are an antimony halide, a tin halide, a tantalumhalide, a titanium halide, a niobium halide, molybdenum halide, an ironhalide, a fluorinated chrome halide, a fluorinated chrome oxide orcombinations thereof. Specific non-exclusive examples of vapor phasefluorination catalysts are SbCl₃, SbCl₅, SbF₅, SnCl₄, TaCl₅, TiCl₄,FeCl₃, CrF₃, Cr₂O₃ bulk or supported, and fluorinated Cr₂O₃ bulk orsupported. Catalyst supports include carbon, alumina, fluorinatedalumina, or aluminum fluoride, alkaline earth metal oxides, fluorinatedalkaline earth metals, zinc oxide, zinc fluoride, tin oxide, and tinfluoride.

In general, the effluent from the fluorination reaction step, includingany intermediate effluents that may be present in multi-stage reactorarrangements, may be processed to achieve desired degrees of separationand/or other processing. For example, in embodiments in which thereactor effluent comprises a compound of Formula (IB), such asHCFC-244bb, the effluent will generally also include HF and HCl. Someportion or substantially all of these components of the reaction productmay be recovered from the reaction mixture via any separation orpurification method known in the art such as neutralization anddistillation, or in the reaction product may be fed in its entirety orin part, but without any separation of components, to the next step,i.e., dehydrohalogenation of the compound of Formula (IB). It iscontemplated, therefore, that the desired compound of Formula (IB), suchas HCFC-244bb, can be used in subpure form, or optionally in partiallypure form or impure form with at least a portion of the effluent fromthe HCFC-244bb production step used as the feed to thedehydrohalogenation step.

In a continuous mode of operation, the desired compound(s) of Formula(IB), such as HCFC-244bb, and other reaction products, such as hydrogenchloride, are preferably continuously removed from the reactor.

II. Dehydrohalogenation of Formula (IB)

One preferred reaction step in accordance with the present invention maybe described by those reactions in which the compound of Formula (IB) isdehydrohalogenated, preferably in certain embodimentsdehydrochlorinated, to produce a compound of Formula (II). In certainpreferred embodiments, the compound of Formula (IB) comprises amonochloro-tetrafluoro-propane, more preferably,2-chloro-1,1,1,2-tetrafluoropropane (HCFC244bb), which is exposed toreaction conditions to produce a reaction product according to Formula(II), preferably comprising tetrafluoropropene, preferably2,3,3,3-tetrafluoropropene HFO-1234yf.

In certain preferred embodiments, the stream containing the compound ofFormula (IB) is preheated to a temperature of from about 150° C. toabout 400° C., preferably about 350° C., and introduced into a reactionvessel, which is maintained at about the desired temperature, preferablyfrom about 200° C. to about 700° C., more preferably from about 300° C.to about 700° C., more preferably from about 300° C. to about 450° C.,and more preferably in certain embodiments from about 350° C. to about450° C.

Preferably the vessel is comprised of materials which are resistant tocorrosion as Hastelloy, Inconel, Monel and/or fluoropolymers linings.Preferably the vessel contains catalyst, for example a fixed or fluidcatalyst bed, packed with a suitable dehydrohalogenation catalyst, withsuitable means to heat the reaction mixture to about the desiredreaction temperature.

Thus, it is contemplated that the dehydrohalogenation reaction step maybe performed using a wide variety of process parameters and processconditions in view of the overall teachings contained herein. However,it is preferred in certain embodiments that this reaction step comprisesa gas phase reaction, preferably in the presence of catalyst, and evenmore preferably in the presence of a fixed bed catalytic reactor in thevapor or gas phase.

In preferred embodiments, the catalyst is a carbon- and/or metal-basedcatalyst, preferably activated carbon (in bulk or supported form), anickel-based catalyst (such as Ni-mesh), metal halides, halogenatedmetal oxides, neutral (or zero oxidation state) metal or metal alloy andcombinations of these. Other catalysts and catalyst supports may beused, including palladium on carbon, palladium-based catalyst (includingpalladium on aluminum oxides), and it is expected that many othercatalysts may be used depending on the requirements of particularembodiments in view of the teachings contained herein. When metalhalides or metal oxides catalysts are used, preferably mono-, bi-, andtri-valent metal halides, oxide and their mixtures/combinations, andmore preferably mono-, and bi-valent metal halides and theirmixtures/combinations. Component metals include, but are not limited to,Cr³⁺, Fe³⁺, Mg²⁺, Ca²⁺, Ni²⁺, Zn²⁺, Pd²⁺, Li⁺, Na⁺, K⁺, and Cs⁺.Component halogens include, but are not limited to, F⁻, Cl⁻, Br⁻, andI⁻. Examples of useful mono- or bi-valent metal halide include, but arenot limited to, LiF, NaF, KF, CsF, MgF₂, CaF₂, LiCl, NaCl, KCl, andCsCl. Halogenation treatments can include any of those known in theprior art, particularly those that employ HF, F₂, HCl, Cl₂, HBr, Br₂,HI, and I₂ as the halogenation source. When neutral, i.e., zero valent,metals, metal alloys and their mixtures are used. Useful metals include,but are not limited to, Pd, Pt, Rh, Fe, Co, Ni, Cu, Mo, Cr, Mn, andcombinations of the foregoing as alloys or mixtures. The catalyst may besupported or unsupported. Useful examples of metal alloys include, butare not limited to, SS 316, Monel 400, Inconel 825, Inconel 600, andInconel 625.

Of course, two or more any of these catalysts, or other catalysts notnamed here, may be used in combination.

The gas phase dehydrohalogenation reaction may be conducted, forexample, by introducing a gaseous form of a compound of Formula (IB)into a suitable reaction vessel or reactor. Preferably the vessel iscomprised of materials which are resistant to corrosion, especially tothe corrosive effects of hydrogen chloride (to the extent that suchmaterial is formed under the dehydrohalogenation conditions) asmentioned above. Preferably the vapor phase reaction vessel containscatalyst, for example a fixed or fluid catalyst bed, packed with asuitable dehydrohalogenation catalyst, with suitable means to heat thereaction mixture to about the desired reaction temperature. The reactionvessel may employ single or multiple tubes packed with adehydrohalogenation catalyst.

The compound of Formula (IB), preferably HCFC-244bb, may be introducedinto the reactor either in pure form, partially purified form, or asportion or entirety of the reactor effluent from the preceding step. Thecompound of Formula (IB), such as HCFC-244bb, may optionally be fed withan inert gas diluent such as nitrogen, argon, or the like. In apreferred embodiment of the invention, the compound of Formula (IB),such as HCFC-244bb, is pre-vaporized or preheated prior to entering thereactor. Alternately, the compound of Formula (IB), such as HCFC-244bb,may be vaporized in whole or in part inside the reactor.

While it is contemplated that a wide variety of reaction temperaturesmay be used, depending on relevant factors such as the catalyst beingused and the most desired reaction product, it is generally preferredthat the reaction temperature for the dehydrohalogenation step is fromabout 100° C. to about 800° C., more preferably from about 150° C. toabout 600° C., and even more preferably from about 200° C. to about 550°C.

In general it is also contemplated that a wide variety of reactionpressures may be used, depending again on relevant factors such as thespecific catalyst being used and the most desired reaction product. Thereaction pressure can be, for example, superatmospheric, atmospheric orunder vacuum. The vacuum pressure can be from about 5 torr (0.0966 psig)to about 760 torr (14.69 psig).

In certain embodiments, an inert diluent gas, such as nitrogen, may beused in combination with the other reactor feed(s). When such a diluentis used, it is generally preferred that the compound of Formula (I),preferably Formula (IB), comprise from about 50% to greater than 99% byweight based on the combined weight of diluent and Formula (I) compound.

It is contemplated that the amount of catalyst use will vary dependingon the particular parameters present in each embodiment. Contact time ofthe compound of Formula (IB), such as HCFC-244bb, with the catalyst incertain preferred embodiments ranges from about 0.5 seconds to about 120seconds, however, longer or shorter times can be used.

Preferably in such dehydrofluorination embodiments as described in thissection, the conversion of the Formula (IB) compound is at least about10%, more preferably at least about 20%, and even more preferably atleast about 30%. Preferably in such embodiments, the selectivity tocompound of Formula (II), preferably HFO-1234yf, is at least about 70%,more preferably at least about 85% and more preferably at least about95%.

In certain preferred embodiments, the process flow is in the down or updirection through a bed of the catalyst. It may also be advantageous toperiodically regenerate the catalyst after prolonged use while in placein the reactor. Regeneration of the catalyst may be accomplished by anymeans known in the art, for example, by passing air or air diluted withnitrogen over the catalyst at temperatures of from about 100° C. toabout 400° C., preferably from about 200° C. to about 375° C., for fromabout 0.5 hour to about 3 days.

In general, the effluent from the dehydrohalogenation reaction step,including any intermediate effluents that may be present in multi-stagereactor arrangements, may be processed to achieve desired degrees ofseparation and/or other processing. For example, in embodiments in whichthe reactor effluent comprises a compound of Formula II, such asHFO-1234yf, the effluent will generally also include HCl and unreactedcompound of the Formula (IB). Some portion or substantially all of thesecomponents of the reaction product may be recovered from the reactionmixture via any separation or purification method known in the art suchas neutralization and distillation. It is expected that unreactedcompound of the Formula (IB) could be recycled, completely or partially,to improve the overall yield of the desired CF₃CF═CH₂ (HFO-1234yf).Optionally but preferably, hydrogen chloride is then recovered from theresult of the dehydrochlorination reaction. Recovering of hydrogenchloride is preferably conducted by conventional distillation where itis removed from the distillate.

Alternatively, HCl can be recovered or removed by using water or causticscrubbers. When a water extractor is used HCl is removed as an aqueoussolution. When caustic is used, HCl is just removed from system as achloride salt in aqueous solution.

In an alternate embodiment of the invention, dehydrohalogenation ofHCFC-244bb can also be accomplished by reacting it with a strong causticsolution that includes, but is not limited to KOH, NaOH, Ca(OH)₂ and CaOat an elevated temperature. In this case, the strength of the causticsolution is preferably from about 2 wt % to about 100 wt %, morepreferably from about 5 wt % to about 90 wt % and most preferably fromabout 10 wt % to about 80 wt %. The caustic:Formula (IB) mole ration,preferably the caustic:HCFC-244bb mole ratio, preferably ranges fromabout 1:1 to about 2:1; more preferably from about 1.1:1 to about 1.5:1and even more preferably from about 1.2:1 to about 1.4:1. The reactionmay be conducted at a temperature of from about 20° C. to about 100° C.,more preferably from about 30° C. to about 90° C. and even morepreferably from about 40° C. to about 80° C. As above, the reaction maybe conducted at atmospheric pressure, super-atmospheric pressure orunder vacuum. The vacuum pressure can be from about 5 torr (0.0966 psig)to about 760 torr (14.69 psig). In addition, a solvent or phase transfercatalyst such as Aliquat 336 may optionally be used to help dissolve theorganic compounds in the caustic solution. This optional step may beconducted using solvents that are well known in the art for saidpurpose. Thereafter, the Formula (II) compound, preferably HFO-1234yf,may be recovered from the reaction product mixture comprised ofunreacted starting materials and by-products by any means known in theart, such as by extraction and preferably distillation. In certainpreferred embodiments, the mixture of HFO-1234yf and any by-products arepassed through a distillation column. For example, the distillation maybe preferably conducted in a standard distillation column at atmosphericpressure, super-atmospheric pressure or a vacuum. Preferably thepressure is less than about 300 psig, preferably less than about 150psig and most preferably less than 100 psig. The pressure of thedistillation column inherently determines the distillation operatingtemperature.

Preferably in such dehydrofluorination embodiments as described in thissection, the conversion of the Formula (IB) compound is at least about60%, more preferably at least about 75%, and even more preferably atleast about 90%. Preferably in such embodiments, the selectivity tocompound of Formula (II), preferably HFO-1234yf, is at least about 70%,more preferably at least about 85% and more preferably at least about95%.

EXAMPLES

Additional features of the present invention are provided in thefollowing examples, which should not be construed as limiting the claimsin any way.

Example 1 Continuous Liquid Phase Preparation of CF₃CFClCH₃ (HCFC-244bb)from CCl₂═CClCH₂Cl

A 1.5″ lD×24″ long PFA-lined pipe was filled with 550 grams of antimonypentachloride liquid phase fluorination catalyst. This was heated toapproximately 95° C., and then fluorinated with 5 moles of anhydroushydrogen fluoride. Then a continuous feed of1,1,2,3-tetrachloropropenewas begun, simultaneous with continuous feedof HF. These feeds were maintained in a mole ratio of HF to 1,1,2,3-TCPof about 17:1, with a residence time of about 1 second. The reactor wasmaintained at about 96° C. Volatiles from the run were collected in adry ice cold trap, analyzed, and found to produce a nearly totalconversion of the 1,1,2,3-tetrachloropropene, with selectivity of about22% to 2-chloro-1,1,1,2-tetrafluoropropane (244bb), and selectivity ofabout 33% to 2-chloro-3,3,3-trifluoropropene (1233xf), and selectivityof about 27% to precursor 2,3-dichloro-3,3-difluoropropene (1232xf) andselectivity of >12% to overchlorinated species 1223xd attributed toexcess Cl₂ feed to the reactor to keep the catalyst active.

Example 2 Continuous Liquid Phase Preparation of CF₃CFClCH₃ (HCFC-244bb)from CCl₂═CClCH₂Cl

Example 1 was repeated except 515 grams of antimony pentachloride wasused, mole ratio of HF to 1,1,2,3-TCP is about 30:1, and the residencetime was about 2.1 seconds, and the pressure in the reactor was allowedto build to about 14 psig. Volatiles from the run were collected in adry ice cold trap, analyzed, and found to produce a nearly totalconversion of the 1,1,2,3-tetrachloropropene, with selectivity of about16.7% to 2-chloro-1,1,1,2-tetrafluoropropane (244bb), and selectivity ofabout 33.5% to precursor 2-chloro-3,3,3-trifluoropropene (1233xf), andselectivity of about 34.6% to precursor 2,3-dichloro-3,3-difluoropropene(1232), and selectivity of >10.0% to overchlorinated species 1223xdattributed to excess Cl₂ feed to the reactor to keep the catalystactive.

Example 3 Batch Liquid Phase Preparation of CF₃CFClCH₃ (HCFC-244bb) fromCCl₂═CClCH₂Cl

To a 1 Liter monel Parr reactor is added 83 grams of SbCl₅ and 300 gramsof HF. After heating to 85° C., the HCl and noncondensibles are ventedto a DIT. Then 50 grams of CCl₂═CClCH₂Cl are quickly added. The mole %ratio of SbCl₅ to CCl₂═CClCH₂Cl is 50/50. There is an immediate exothermand the temperature rises to 97° C. almost instantaneously. The variaccontrolling the heater is turned off and the reaction held between 97and 87° C. for an hour. The pressure rises to 400 psig and levels off. Avapor sample is taken into gas bags containing DI H₂O (to absorb the HFand HCl prior to analysis). A GC of the gas bag sample shows 53.5 GCarea % 244bb, 1.46 GC area % overfluorinated species HFC245cb, 6.6 GCarea % overchlorinated species 1223xd along with 1233xf precursor,1232xf precursor, and some C6 compounds that may be dimers. Theconversion of CCl₂═CClCH₂Cl on a GC area % basis is 100%.

Example 4 Conversion of CF₃CFClCH₃ (HCFC-244bb) to CF₃CF═CH₂ inContinuous Gas-Phase

This example illustrates the continuous vapor phase dehydrochlorinationreaction of 2-chloro-1,1,1,2-tetrafluoropropane(244bb)→2,3,3,3-tetrafluoropropene (1234yf)+HCl. The dehydrochlorinationcatalyst is 10 wt % CsCl/90 wt % MgF₂.

Conversion of HCFC-244bb into HFO-1234yf was performed using Monelreactor (ID 2 inch, length 32 inch) equipped with a Monel preheater (ID1 inch, length 32 inch) which was filled with Nickel mesh to enhanceheat transfer. The reactor is filled with 2.0 L of pelletized 10 wt %CsCl/90 wt % MgF₂ dehydrochlorination catalyst. Nickel mesh is placed atthe top and at the bottom of reactor to support the catalyst.Multi-point thermocouple is inserted at the center of the reactor. Thecatalyst is pretreated in dry N2 flow for 6 hours at the temperature of480° C. Then the feed with the composition 95GC % 244bb/3.1GC %1233xf/0.35GC % 245cb is introduced into the reactor at the rate of 1.0lb/hr. The feed is vaporized prior entering the reactor preheater. Thebottoms of the distillation column is discharged and recycled into thereactor. The feed rate is maintained constant at 1.0 lbs/hr and bothtemperature and pressure are varied. Temperature gradient throughout thereactor is within about 3-5° C. The productivity of the catalyst isestimated at 3-6 lbs/hr/ft³. The highest productivity is observed at470° C. and 45 psig, and the lowest productivity is observed at 480° C.and 3 psig pressure. The reaction products are fed into the causticscrubber to remove HCl by-product. Then the product stream is passedthrough a column filled with desiccant to remove residual moisture.Oil-less compressor was used to feed crude product into the distillationcolumn that was maintained at 30-45 psig pressure. Distillation wasperformed in a continuous mode and the take-off rate was equal to therate of production of HFO-1234yf in the reactor. The purity of distilled1234yf is 99.9GC %+. GC analysis of the distillate shows presence oflight impurities with a ppm level of heavy impurities.

The following conversions and selectivities are achieved:

480° C. at 3 psig-244bb conversion˜30%, Selectivity to 1234yf˜97%

480° C. at 20 psig-244bb conversion˜47%, Selectivity to 1234yf˜96%

470° C. at 20 psig-244bb conversion˜36%, Selectivity to 1234yf˜97%

470° C. at 45 psig-244bb conversion˜53%, Selectivity to 1234yf˜96%

460° C. at 45 psig-244bb conversion˜38%, Selectivity to 1234yf˜98%

Reaction Data

Conditions: Feed 95GC % 244bb/3.1GC % 1233xf/0.35GC % 245cb; 2.0 L of 10wt % CsCl/90 wt % MgF₂ catalyst; 1.0 lb/hr feed rate.

Time on-stream conversion Selectivity to Temperature Pressure (hrs.) of244bb (%) 1234yf (%) (° C.) (psig) 0.25 93.30 82.42 484.30 3.00 0.8067.61 90.38 489.00 3.90 1.43 47.78 94.14 479.80 3.50 2.27 31.98 97.34479.80 3.40 3.32 29.36 97.70 478.80 3.80 4.32 26.24 97.56 478.70 2.805.23 28.45 97.88 480.30 2.90 6.20 30.53 98.01 480.30 3.20 6.80 30.9198.13 478.40 3.30 7.37 28.36 97.88 478.80 2.90 7.93 29.01 97.84 479.303.10 8.48 29.95 97.91 478.30 3.30 9.05 26.61 96.76 479.60 2.70 9.6227.98 96.12 476.80 2.90 10.20 28.84 96.66 480.20 3.00 10.70 29.70 97.16480.50 3.10 11.22 29.30 97.62 480.30 3.30 11.72 30.47 97.65 480.70 3.3012.25 29.57 97.59 480.30 3.30 12.75 29.83 97.92 480.00 3.50 13.27 30.1098.23 479.60 2.80 13.78 28.73 97.02 480.10 2.80 14.28 29.54 97.31 480.802.90 14.80 29.95 98.05 479.80 2.90 15.30 29.71 97.98 480.60 3.00 15.8030.50 98.14 480.80 2.90 16.32 30.68 97.96 481.50 3.10 16.83 32.21 97.79482.50 3.10 17.35 30.37 97.68 478.00 3.20 17.85 27.67 97.18 479.20 3.3018.40 28.06 96.50 477.50 3.20 18.95 27.84 96.58 478.20 3.40 19.50 28.8596.66 482.30 3.40 20.18 32.52 97.55 480.00 3.40 20.87 29.15 97.47 480.103.20 22.90 64.16 97.20 478.90 17.40 23.65 47.32 96.23 477.80 17.50 24.3247.80 96.81 478.60 17.00 25.00 47.45 96.83 479.40 16.90 26.02 47.1096.84 479.50 18.50 26.78 46.99 97.34 478.60 20.00 27.38 48.61 97.45478.80 20.00 28.22 47.00 97.41 477.80 20.00 28.93 48.53 96.40 480.0020.00 29.63 46.61 96.10 477.70 20.00 30.23 49.28 96.14 480.80 20.0030.83 44.30 96.11 477.70 20.00 31.45 48.53 96.18 479.50 20.00 32.0545.03 97.45 477.70 20.00 32.72 48.94 97.09 480.10 20.00 33.30 45.1096.24 478.00 20.00 33.83 46.72 96.25 479.70 20.00 34.37 49.04 96.21479.30 20.00 34.90 46.86 96.34 477.80 20.00 35.42 41.57 97.52 474.6020.00 35.95 38.83 97.44 469.40 20.00 36.48 31.20 97.45 468.40 20.0037.02 34.86 96.45 470.10 20.00 37.55 35.41 96.44 470.20 20.00 38.0737.17 97.71 469.90 20.00 38.63 36.72 97.31 471.10 20.00 39.15 36.6697.68 470.00 20.00 39.67 37.41 97.85 470.80 20.00 40.20 36.43 97.86469.40 20.00 40.73 36.10 97.98 469.20 20.00 41.27 35.34 97.97 470.5020.00 42.05 37.63 96.08 472.00 20.00 42.57 38.60 97.20 470.30 20.0043.12 57.72 96.75 469.60 45.00 43.65 53.72 95.42 467.10 45.00 44.1751.28 94.83 468.70 45.00 44.68 51.60 96.39 467.50 45.00 45.20 52.5296.36 469.80 45.00 45.72 53.43 96.65 468.90 45.00 46.77 51.14 95.44468.50 45.00 48.15 53.38 97.23 470.70 45.00 49.32 54.53 97.21 470.9045.00 50.88 51.94 97.21 469.40 45.00 52.35 39.24 97.70 459.60 45.0053.75 39.15 97.19 459.30 45.00 55.03 38.45 97.63 458.30 45.00 56.5737.19 97.61 457.50 45.00 57.85 37.44 97.88 458.90 45.00 58.93 38.1897.91 458.80 45.00 59.98 37.98 98.04 460.10 45.00 61.05 39.77 97.43463.00 45.00 62.10 42.11 97.92 462.20 45.00 63.20 41.11 97.74 459.1045.00 64.27 39.64 98.05 460.60 45.00 65.32 40.98 97.70 461.40 45.00

1. A method for producing fluorinated organic compounds comprisingconverting at least one compound of Formula (IA):C(X)₂═CClC(X)₃  (IA) to at least one compound of Formula (II):CF₃CF═CHZ  (II) where each Z is H or Cl and X is independently H, F, Cl,I or Br.
 2. The method of claim 1 wherein at least one of said X on theunsaturated terminal carbon is F, Cl, I or Br.
 3. The method of claim 1wherein at least one of said X on the unsaturated terminal carbon is Cl.4. The method of claim 1 wherein and Z is H.
 5. The method of claim 4wherein said at least one compound of Formula (IA) comprises at leastone tetrachloropropene.
 6. The method of claim 1 wherein said at leastone compound of Formula (IA) comprises at least one tetrachloropropene.7. The method of claim 1 wherein said at least one compound of Formula(IA) comprises CCl₂═CClCH₂Cl.
 8. The method of claim 1 wherein saidconverting step comprises a first exposing step comprising exposing thecompound of Formula (IA) to a substantially single set of reactionconditions effective to produce at least one chlorofluoropropane andsecond exposing step comprising exposing said at least onechlorofluoropropane to one or more sets of reaction conditions effectiveto produce a compound of Formula (II).
 9. The method of claim 8 whereinsaid at least one chlorofluoropropane is in accordance with Formula(IB):CF₃CClX′C(X′)₃  Formula (IB) where each X′ is independently F, Cl or H.10. The method of claim 9 wherein said compound of Formula (II)comprises 2,3,3,3-tetrafluoro-1-propene (HFO-1234yf).
 11. A method forproducing fluorinated organic compounds comprising: (a) reacting in aliquid phase in the presence of at least a first catalyst a compound ofFormula (IA):C(X)₂═CClC(X)₃  (IA) where each X is independently H or Cl, to produceat least one compound of Formula (IB):CF₃CClX′C(X′)₃  Formula (IB) where each X′ is independently F, Cl or H;and (b) reacting said compound of Formula (IB) under conditionseffective to produce a compound of Formula (II):CF₃CF═CHZ  (II) where each Z is H or Cl.
 12. The method of claim 11wherein said compound of Formula IA is a tetrachloropropene.
 13. Themethod of claim 12 wherein said tetrachloropropene is selected from thegroup consisting of CCl₂H—CCl═CClH and CCl₃—CCl═CH₂.
 14. The method ofclaim 13 wherein said compound of Formula (II) comprises2,3,3,3-tetrafluoro-1-propene (HFO-1234yf).
 15. A method for producingfluorinated organic compounds comprising: (a) reacting in a liquidphase, in the presence of at least a first catalyst, and at atemperature of about 30° C. to about 200° C., a compound of Formula (I):C(X)_(m)CCl(Y)_(n)C(X)_(m)  (I) where each X is independently H, F, Cl,I or Br, and each m is independently 2 or 3, and n is 0 or 1, to produceat least one compound of Formula (IB):CF₃CClX′C(X′)₃  Formula (IB) where each X′ is independently F, Cl or H.16. The method of claim 15 wherein m is 3 and n is
 1. 17. The method ofclaim 16 wherein X is H or Cl.
 18. The method of claim 15 wherein thecompound of Formula (I) is at least one of CCl₃—CClH—CClH₂,CCl₂H—CCl═CClH, and CCl₃—CCI═CH₂.
 19. The method of claim 15 furthercomprising (b) reacting said compound of Formula (IB) under conditionseffective to produce a compound of Formula (II):CF₃CF═CHZ  (II) where each Z is H or Cl.
 20. The method of claim 19wherein the compound of Formula II is 2,3,3,3-tetrafluoro-1-propene(HFO-1234yf).